Roofing



p 11, 1934- s w. .CHAFFEE Er AL 1,973,5

ROOFING Filed June 14 1930 INVENTORS STEWART w. CHAF'FEE RALPH P. MULLER ATTORNEY Patented Sept. 11, 1934 PATENT OFFICE ROOFING steam w. China, New York, and Ralph r;

Muller, St. George, N. I.

' Application June 14, 1930, Serial No. 461,258

' 7 Claims. (01. 108-6) This invention relates'to the art of waterproof ing the surfaces of roof structures and has for an object the provision of a new type of roofing or siding structure involving a novel method of applying'ornamental designs thereto.

The invention is an improvement on the process set forth in the application ,of Ralph P. Muller, Serial No. 423,885, filed January 27, 1930.

In relation to the invention herein, the invention in that application dealt with the construction of a water-proof roof structure by the application of a waterproofing substance, in liquid or plastic state, to a moisture-pervious roof surface; materials such as emulsified asphaltum were indicated for that purpose. The liquid or plastic substance, for the purposes of the invention, was pneumatic, so that its transportation from a source of supply to the roof surface to be coated, could be effected through a conduit without the necessity of handling such material at the roof level in the customary manner of mopping-on. The substance, under pressure, is impelled, preferably in the form of a spray, surface td'be coated and thereby is uniformly distributed over the roof surface. In like manner, and either simultaneously with, or at a timed interval after, the applicationof the liquid or plastic substance, grit particles are conveyed by a pneumatic stream for application to the coating surface and, byeffect of .the transporting stream, are driven into the mastic base formed by the applied substance and become embedded therein. I

It is an object of the'invention to produce, as a substantially unitary formation, a roof surface having a substantially continuous coating of a moisture-impervious compound to form a coating which may be characterized as similar in effect 'to monolithic construction. This'moisture-impervious coating may, pervious coating still remains substantially plastic, then be covered with one or more coatings of grit particles, and then, while the condition of plasticity still continues, designs may be produced in the coated roof structure. One such instance of design formation involves. imbedding the particles at predetermined areas.

Other objects of this invention will hereinafter be set forth, or will be apparent from the-description 'and the drawing, in which is illustrated a selection from different methods of carrying out the invention. v

,The invention, however, is not intended to be restricted to any particular cpnstructionor arrangement of parts, or to any particular appliat the while the moisture-imwith cut-out portions,

cation thereof, or to any specific manner of use,

or to any particular method of operation, or to any of the various details or steps thereof, herein shown and/or described, as the same may be modified in various particulars or be applied in 6. many ,varied relations without departing from the spirit and scope of the claimed invention, the selected methods herein illustrated and described merely being some of various possible exemplifications of the invention.

0n the drawing, in which the same reference. characters refer to the same parts throughout, and in which are disclosed such selected exemplifications:

Fig. 1 is a view in perspective, illustrating gen- 7 erally a method of applying the moisture-impervious coating and the grit particles, together with a method for delineating a design upon the surface'after such application;

Fig. 2 is a view, in vertical cross-section, illus- 7 trating one method of delineating a design;

Fig. 3 is a view, similar to Fig. 2, illustrating another method of delineating a design; Fig. 4 is a; plan view of a portion of the roof surface prepared in accordance with the invention herein,. illustrating its appearance after a design has been delineated, as, for instance, by the method illustrated in Fig. 2', I

Fig. 5 is a view, similar to Fig. 2, illustrating a roof structure produced in accordance wit another method herein set forth; and

Fig. 6 'is a-plan view of a portion of a roof structure prepared inaccordance with the invention herein, as, for instance, by the method illustratedby Fig. 5.. 9 x The invention consists in stamping or impressing designs on the roof surface which has been waterproofed and surfaced by the application of the waterproofing film of emulsified asphaltum 9 or like bituminous or hydrocarbon material and vof the granuIar surfacing, in accordance with the invention set out in the aforesaid Muller application. This is preferably accomplished by a roller provided with suitable raised portions which, when pressed into the surface .on which the design is desired to be applied, embed the surfacing material in the mastic coating and indent the lines of the desired design into the coated surface. This delineates the desired design in lines or areas which are exposed in the color of the basic waterproofing material. Instead of rollers with raised portions, we contemplate using rollers with depressed portions, or

and, if desired, a stamp 11 may be used for applying the desired design in the coating.

The application of the design is preferably made immediately after the surfacing material is applied and before the mastic coating has had an opportunity to set. In this manner, the impressions may be easily applied and the surface will thereafter set so as to preserve the design outline which thus results from forcing the surfacing into the water-proof mastic material. In this manner the surfacing material loses its I identifying color throughout the impressed detrative purposes, at a sign and the whole surface in a design outlined in of the basic material.

If desired, the roofing surface may be now sprayed with a grit of contrasting texture or color, that is, contrasting with the texture or color of that originally applied. This grit thus is forced into the areas indented by the designimpressing device so that a covering surface of pleasing and ornamental appearance is obtained.

The design may, if desired, be impressed before any surfacing material at all has been applied, and a subsequent spraying of one color of grit may be utilized to give a surface having an ornamental design impressed thereon which is covered uniformly by an adhering layer of the desired color of grit.

If desired, a colored design may be applied to the surface covering in a slightly modified manbecomes delineated the same color as that ner. This consists in forming a surface in preembedded in. the coating so that a contrasting effect is obtained along the lines or areas delineated by the impressing apparatus.

When a second application of colored grit is made, the lines of demarcation are delineated not only in color but also in relief, as the depressed portions are clearly discernible and accentuate the design in creating a shadow effect. We contemplate using colored asphalt as a base, thus enabling a color contrast to be created without the necessity granular material.

Instead of impressing a design, we contemplate achieving a similar result by spraying the grit through stencils, thus obtaining a' wide variety of designs and, if colored asphalt or colored waterproofing material along with colored grit is used, a variety of colored designs is'also obtained. On the drawing there are illustrated certain exemplifications of the invention. For such illustration, only, particular reference is made to a roof construction 10, here shown as having a boundary wall 12. Roor surface 14, as here shown, is formed from boards 16, between which crevices or grooves 18 will then appear. For illuschimney 20, a broken portion 22 has been designated, such broken portion to be repaired in accordance with certain features of this invention, and also as described and claimed in the application of Ralph P. Muller, hereinbefore referred to.

In making a roof construction of the type here described, material such as an asphalt emulsion ,will cause the delineation of using different colored emulsion, grit particles may be sprayed upon the surface coating of emulsion.

On the drawing, nozzles 24 and 26 are intended to illustrate, respectively, a nozzle for spraying the asphalt emulsion, and a nozzle for spraying the grit particles. As shown, the emulsion is sprayed so as to coat over the roof surface defined by board 16,-whichcoating may even be extended to seal crevices 28 at the junction of roof surface 14 with boundary wall 12 and chimney 20. Base coating 30, for this purpose, may be extended up the side of the boundary wall a sufficient distance to assure a proper seal between roof surface and boundary wall.

Following immediately uponthe application of coating 30, or at a sufficient interval so that the emulsion coating will still be plastic and of sufficient fluidity to receive the sprayed particles, permit them to become imbedded to a slight degree in the coating, and become bonded to the coating, nozzle 26 is made efiective. Grit particles 32, thus sprayed, define their 'layer 34. In the exemplification shown on the drawing, the two spraying operations are carriedon substantially simultaneously. In such case, a section 36 of coating 30 will be clear of particles for a predetermined interval to permit some hardening of the coating before the particles fall upon it.

When broken portion 22 will be reachedand such portion is generally nothing more than a frayed or worn section of the. timbers or of the roofing material previously applied, in the case of repairs to a roof previously constructed, or other defects in the materialthe coating composition may be made effective to fill up that broken portion completely, sealing also, as it does, crevices 18 and 28, and other similar defects in the ordinary roof surface.

Furthermore, as the two the roof surface, there may eration a design-forming member, such as a roller 38, as shown in Fig. 2. By reason of certain raised portions 40 on the surface of the roller, it

nozzles move along be brought into opcoated surface. These raised portions cause the grit particles against which they come into play, to sink into the\still plastic water-impervious coating, and thus to permit" to appear, as a part of the design, not the grit particles, but the base coating itself. This operation of delineating the design may be carried on simultaneously with the coating of the surface, as shown in Fig. 1. It may be delayed somewhat after the grit and emulsion coatings have been applied, so long as the coating on the roof surface still remains plastic at the time the rolleror similar designforming means comes into action.

Figs. 2, 3, and 5 demonstatea number of different exemplifications of methods by which the invention may be eifectuated, although, of course, they -do not completely encompass all the possible variations. In Fig. 2, roller 38, having portions of its surface raised, has been shown; in Fig. 3, an embossing roller 42 is illustrated. In the latter case, cavities 44, defined in the roll surface, receive grit particles 32 and some of coating .30, which, being forced upwardly as the roller moves over the surface, produce theof a design in.the-.

delineation of the desired design. A design, thus determined, will appear on the roof somewhat as in Fig. 4, with hills and valleys imprinted therein, the grit particles being imbedded'in the base coating at areas 46, and being left substantially unaffected at areas 48, in the positions they assumed on their initial impact when sprayed.

particles'was controlledso that most all came;

to rest in the grooved or depressed areas 52, while those striking upon areas 50, which are in substantial relief, moved along further until they reached such a depression as defined by areas 52..

In this manner, a surface is produced, in appearance somewhat as shown inFig. 6. In such case.

layers, while, in others, the bottommost layer will have disappeared.

Many other changes could be effected in the particular apparatus here exemplified, and in the method of operation set forth, and in specific de= tails thereof, without substantially departing from the invention intended to be defined in the claims, the specific description being merely clearly to demonstrate practical methods for carrying out the spirit of the invention.

Having thus described our invention we claim: 1. The process of producing, as a single continuous unit, an ornamental roof surface upon the outer exposed surface of the completely assembled roof structure of a building, wherein the exposed surface of the roof structure is initially moisture-pervious, which includes the steps of spraying uniformly over the moisture-pervious surface, substantially throughout its extent, a coating of waterproofing liquid compound; immediately thereafter and while the waterproofing liquid compound still remains plastic spraying upon, and substantially all over the waterproofing liquid compound coating, aplurality of distinctly differently colored coatings of grit par ticles; and then producing designs in the coated surface by imbedding the particle layers within the waterproofing liquid compdund coating at limited and distinctly defined areasw 2. The process of producing, as a single continuous unit, an ornamental roof surface upon the outer exposed surface of 'the completely as- .sembled roof structure of a building,.wherein the bedding the particle layers within the waterproofing liquid compound coating at limited and distinctly defined areas; and then spraying other grit particles over the coating.

3. The process of producing, as a single continuous unit, an ornamental roof surface upon the outer exposed surface of the completely assembled roof structure of a building, wherein the exposed surface of the roof structure is initially moisture-pervious, and after the moisturepervious surface has been made moisture-impervious by the application of a coating of waterproofing liquid compound to the moisturepervious surface, which includes'the steps of: depositing upon the waterproofing liquid compound coating while it still remains plastic a plurality of distinctly differently colored coatings of'grit particles extending substantially all over the waterproofing liquid compound coating, and then producing designs in the coated surface by imbedding. the particle layers within the waterproofing liquid compound coating only at limited and distinctly definediareas of the coated surface.

:4. The process of producing, as a single continuous unit, an ornamental roof surface upon the outer exposed surface of the completely assembled roof structure of a building, wherein the exposed surface of -the roof structure is initially moisture-pervious, which includes the steps of:

spraying uniformly over the moisture-pervious surface, substantially throughout its extent, a coating of waterproofing liquid compound; depositing upon the waterproofing liquid compound coating, substantially immediately after the application of that coating, and whileit is still in the plastic state, an uniform coating of grit particles extending substantially all over the waterproofing liquid compound coating; and then producing embossed designs at distinctly defined areas in the layer by hearing with an embossing roller upon limited and distinctly defined areas of the coated surface to imbed the particles within the waterproofing liquid compound coating only at the areas to which pressure is applied and to effect a rise above the existing level of the level of the coated surface immediately around such impressed areas. 5

5. The process of producing, as a single continuous unit, an ornamental roof surface upon the outer exposed surface of the completely assembled roof structure of a building, wherein the exposed surface of the roof structure has inherent moisture-pervious characteristics, which includes the steps of spraying uniformly upon the exposed moisture-pervious surface, substantially throughout its extent, a coating of waterproofing liquid compound to form an unitary moisture-impervious layer for the surface; immediately thereafter spraying upon the waterproofing liquid compound coating while it remains plastic, a coating of grit particles extending substantially all over-the liquid compound coating; and then bringing pressure to bear upon limited and definitely defined areas of the coated surface to imbed the particles within the waterproofing liquid compound coating only at the areas subjected to pressure.

i 6. The process of producing, as a single continuous unit, an ornamental roof surface upon the outer exposed'surface of the completely assembled roof structure of a building, after the exposed moisture-pervious surface has been made moisture-impervious by the application of a coating of waterproofing liquid compound, which includes the steps of: spraying upon the waterproofing liquid compound coating while it still remains plastic a .coating of grit particles extending substantially all over the coating, and then bringing pressure to bear/upon limited and definitely defined areas: of the coated surface to imbed the. particles within the coating only ,at the areas subjected to pressure.

7. The process of producing, as a single continuous unit, an ornamental root surface upon the outer exposed surface of the completely assembled roof structure of a building, wherein the exposed surface of the roof structure is moisture-pervious by inherent characteristics of its construction, which includes the steps of: spraying substantially uniformly over the surface a coating of a colored waterproofing liquid compound, depositing upon and substantially uni- 

